State based full and empty control for rechargeable batteries

ABSTRACT

State based full and empty control for rechargeable batteries that will assure a uniform battery empty condition, even in the presence of a load on the battery. A fuel gauge provides a prediction of the open circuit voltage of the battery, and when the predicted open circuit voltage of the battery reaches the predetermined open circuit voltage of an empty battery, the load is terminated, after which the battery will relax back to the predetermined open circuit voltage of an empty battery. A similar technique is disclosed for battery charging, allowing faster battery charging without overcharging. Preferably an RC battery model is used as the fuel gauge to provide the prediction, but as an alternative, a coulomb counter may be used to provide the prediction, with error correction between successive charge discharge cycles.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 14/715,392 filed May 18,2015, which is a divisional of U.S. patent application Ser. No.13/311,297 filed Dec. 5, 2011, which claims the benefit of U.S.Provisional Patent Application No. 61/420,627 filed Dec. 7, 2010.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to charging methods for rechargeablebatteries.

2. Prior Art

The standard definition of empty for a (rechargeable) battery is when aparticular battery terminal voltage defined as the empty voltage occurs.This definition is naïve and simple-minded, since the external voltagesays little about the internal state of the battery. The real reason forthis definition is that there has been no better way to define empty,and battery vendors must provide a rule of some sort, so they define avoltage.

Other approaches have been used, but they lose capacity as a function ofload, temperature, battery characteristic, and empty voltage. Forinstance, coulomb counters have been used, but a coulomb counter musttraverse full and empty often or error accumulates. Also there is noreliable method to recognize actual light-load capacity shrinkage, sincethe capacity to an empty voltage is dependent on the actual load fromeach cycle, because of battery impedance. Another approach uses batteryimpedance to predict traditional cell voltage definition of empty. Stillanother approach is to use a previous model gauge approach, that is, touse empty compensation to predict traditional cell voltage definition ofempty, i.e., to account for the relaxation of a battery after a load isremoved so that after relaxation, the open circuit voltage of thebattery should be the predetermined empty voltage. All of these previousapproaches result in variation of capacity utilization and residualcharge which is unused.

Maxim Integrated Products, assignee of the present invention,manufactures and sells voltage-based battery fuel gauges that model thebattery itself, and track the state of charge of the battery independentof the current load, if any, on the battery. In particular, an idealbattery of a given amp-hour capacity would provide a constant voltageoutput until outputting its total amp-hour capacity, after which thebattery voltage would fall to zero. Real batteries, however, exhibit adecrease in terminal voltage with a decreasing state of charge and/or anincreasing current load. Some batteries have a terminal voltage thatfalls off rapidly as the fully discharged state is approached.

One battery model that can be used is a simple RC network, where Rrepresents the internal impedance of the battery and C represents theequivalent capacitance of the battery for any given open circuit batteryvoltage. R can be easily determined by loading and unloading thebattery, and to the first order, generally can be taken as a constantvalue. The apparent capacitance C in the simple RC model at any point inthe open circuit voltage versus state of charge curve is equal to theinverse of the rate of change of the open circuit voltage of the batteryper amp-hour of current withdrawn. Consequently one may plot theequivalent capacitance of the battery versus open circuit voltage, andthe plot of capacitance versus battery open circuit voltage can beapproximated as piecewise constant C values over various increments ofthe open circuit voltage. Of course R and C may be scaled as desiredwithout effecting the result. Then on charging and discharging, usingthe RC model and sensing the battery terminal voltage and current to andfrom the battery, the open circuit voltage of the battery can becalculated to determine the state of charge of the battery independentof the current flow. Of course one can also use a more complicatedbattery model to account for such things as long term recovery of thebattery (a long time constant component), temperature, variations inbattery impedance (R), current, etc. Also a coulomb counter can be usedwith such modeling, the coulomb counter increasing the transient andshort term accuracy of the modeling and the modeling increasing the longterm accuracy of the coulomb counter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1a through 1d depict the state based empty vs. the traditionalmethods of defining empty.

FIG. 2 illustrates the fast safe charging of a rechargeable batteryusing the state based full as defined by the present invention.

In the description to follow, whenever exemplary values are given, it isassumed that the battery is a Li-ion battery, though the principles ofthe present invention are applicable to other types of rechargeablebatteries as well.

One embodiment of the present invention takes advantage of the fact thatby modeling the battery, such as in the prior art described above, onecan know the open circuit voltage of the battery, even when the batteryis under a load. The particular model used is not of great importance,as any reasonable prediction of the open circuit voltage of a batteryunder load will be better at determining the battery state of chargethan simply using the terminal voltage of the battery for that purpose.Thus the present invention allows the setting of state based full andempty conditions of the battery, and adhering to those states even whenunder a load.

By way of example, state-based empty control allows the immediatebattery terminal voltage to be disregarded and allow full batteryutilization across a wide range of load conditions, such as loadvariations, temperature variations, battery variations, age, etc.Normally the impedance drop of a battery would be responsible forcapacity loss. Additionally, state based full and empty control reducesthe overall error budget which allows for better battery utilization. Inparticular, state based full and empty control takes advantage of thecapacity of the specific battery being monitored, rather than limitingthat capacity because of battery impedance. State based full and emptycontrol can also be used to provide additional well controlledlimitations on battery charge and discharge limits for the purpose ofbattery lifespan extension. This is especially important in applicationswhich demand more than the typical 5 year battery lifespan (such asautomotive, which demands more than 10 years).

FIGS. 1a through 1d depict the state based empty vs. the traditionalmethods of defining empty. In these curves, the thin lines or curvesrepresent traditional methods and the thick lines or curves representthe state based empty of the present invention. The curves for Q(@C/2)represent the discharge rate under a heavy load, while the curves forQ(@C/8) represent the discharge rate for a light load. The traditionalmethod stops at the same immediate battery voltage independent of load(3.0 volts in FIG. 1b ), yet stops or settles at a different batterystate which is evidenced by the difference in the following relaxationvoltage. The state of the battery (open circuit battery terminalvoltage) is different in each of these two cases, as can be seen inFIGS. 1a and 1c . However, the state based empty of the presentinvention stops at the same state (same open circuit battery terminalvoltage as shown in FIG. 1c ), but allows for a different immediatebattery voltage when stopping (FIG. 1d ), and manages the followingrelaxation state to be relatively independent of load condition, tosettle on the same open circuit voltage. To achieve this, the fuelgaugemust be capable of accurate OCV predictions, which is a compoundedchallenge near empty when OCV and resistance become very nonlinear.

The state based full condition also provides better control of the fullstate for optimized charge control and charge speed. This can beachieved in life-span optimized applications, such as 3-year warranteesituations (currently seen in the industry for Apple and HP laptopcomputers). In these applications the charge voltage is often reducedfrom 4.2V to 4.1V to improve battery lifespan, since time at full oftendominates as a cause of battery aging (especially for users who keeplaptops always plugged in). The common solution for this lifespanextension is to simply charge to 4.1V instead of 4.2V. A smarter way toachieve the same lifespan improvement is to charge to a higher immediatebattery terminal voltage, such as 4.2V, but change charge termination tooccur at the same state (same open circuit battery terminal voltage) asthe prior art 4.1V charging. This provides lifespan extension (andwarrantee extension) while simultaneously providing a feature toaccelerate charging.

This concept is depicted in the FIG. 2. The sloped line at the leftrepresents the charging rate. For an extended battery life in the priorart, the charging voltage peaks at 4.1 volts, and after a period oftime, the charger is shut off and the battery open circuit voltagerelaxes to 4.05 volts. With the present invention, charging can proceedto 4.2 volts for a shorter time to achieve the same state of charge,with the relaxation starting earlier and being more pronounced toultimately reach the same open circuit voltage of 4.05 volts, therebycharging to the same open circuit voltage as the prior art chargingtechnique produces (4.05 volts). Again this is achieved with a fuelgaugethat manages an accurate OCV prediction. This same concept might be usedfor the 4.2V charging by overcharging to 4.3V but stopping early to thesame state as 4.2V full. However, one should verify that going to aneven higher charging voltage than specified by the battery manufacturer,even for a short time, would possibly somehow not achieve the desiredeffect or further shorten the battery life.

In extreme long lifespan applications, it is common to charge to only70% and discharge to only 30% in order to maximize the total batterylife utility (cycles*capacity). This is done in space applications wherethe service cost is extreme, but it is also done in automotiveapplications where the vehicle must last more than 10 years. State basedfull and empty control can extend this existing concept by moreaccurately and directly managing battery state by the open circuitprediction and perception used in the present invention.

Thus by having a good prediction of the battery state, one can moreaccurately define the full and empty states and utilize more of thebattery capacity without risk of overcharging or overdischarging thebattery. As a result, state based full and empty control should improverun-time by more than 30% for an aged battery because of its higherimpedance. At cold temperatures (such as 0° C.) a battery can lose overhalf the capacity. At cold, state based full and empty control canimprove run-time by more than 50%. When the loading on the battery ishigh, there is much more voltage drop, and battery voltage is moredisassociated with battery state. At 1 C load, state based full andempty control can improve run-time by more than 20% on some newbatteries, relative to higher 3.4V and 3.3V empty voltages.

Fuel-gauging is a real-time activity and cannot be allowed to depend ona future relaxed condition which happens after the critical event(empty) is already past. Real-time fuel-gauging must make itspredictions while there is loading present. By defining empty accordingto a prediction of the open circuit voltage, the fuel-gauge can actuallylimit and manage the empty state of the battery, instead of using asimple immediate voltage. This will be typically performed with 2% or 3%battery capacity held in reserve, i.e., discharge will be terminated at2% or 3% actual battery state of charge to leave a reserve capacity.That reserve capacity may be used to support:

-   -   1. Reserve & background functions (saving data, shutting down,        maintaining clock).    -   2. Error budget (no fuel-gauge can be perfect).    -   3. Protect the battery from overdischarge. Discharging down to        the bottom 1% of the battery could injure the battery and will        accelerate aging.

Another technique that could be used to practice the present inventionis to use a coulomb counter type of fuel gauge and note the open circuitvoltage of the battery after each discharge and after the battery has anopportunity to relax. Then the coulomb count from full to empty may beadjusted up or down for the next charge discharge cycle based on theerror between the open circuit voltage of the battery after relaxationand the intended open circuit voltage of the battery representing empty.Similarly, the open circuit voltage of the battery after each charge andafter the battery has an opportunity to relax could be noted. Then thecoulomb count from empty to full may be adjusted up or down for the nextdischarge charge cycle based on the error between the open circuitvoltage of the battery after relaxation and the intended open circuitvoltage of the battery representing full.

While this could work, it has the disadvantage that it is dependent onthe habits of the device user even more than the typical coulombcounter. In particular, not only may the user of the device not fullycharge the battery between discharges, which allows drift in the coulombcount, but the user may initiate recharging right after an indicatedempty occurs, so that an accurate reading of open circuit voltage afteran empty is indicated is not obtainable. Accordingly the battery modelmethod is preferred, though the specific battery model used is itself amatter of preference and the model itself is not a part of thisinvention.

Thus the present invention has a number of aspects, which aspects may bepracticed alone or in various combinations or sub-combinations, asdesired. While certain preferred embodiments of the present inventionhave been disclosed and described herein for purposes of illustrationand not for purposes of limitation, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.

What is claimed is:
 1. A method of determining an empty state of arechargeable battery comprising: predicting an open circuit voltage ofthe battery, even in the presence of a variable load on the battery;predetermining an open circuit voltage at which the battery is to beconsidered fully discharged that is independent of the variable load onthe battery; in the presence of varying loads on the battery, allowingthe battery to discharge to a terminal voltage below the open circuitvoltage at which the battery will be considered discharged until theopen circuit voltage prediction reaches the open circuit voltage atwhich the battery is to be considered fully discharged; terminating thedischarging when the predicted open circuit voltage of the batteryreaches the open circuit voltage at which the battery is to beconsidered fully discharged.
 2. The method of claim 1 wherein the opencircuit voltage of the battery is predicted using a fuel gauge.
 3. Themethod of claim 2 wherein the fuel gauge is a simulated battery model.4. The method of claim 3 wherein the battery model is a resistorcapacitor battery model.
 5. The method of claim 2 wherein the fuel gaugecomprises a voltage model fuel gauge and a coulomb counter.
 6. Themethod of claim 2 wherein the fuel gauge comprises a resistor capacitorbattery model and a coulomb counter.
 7. The method of claim 1 furthercomprising determining a full state of the battery, wherein the batteryis a rechargeable battery, by; predetermining an open circuit voltage atwhich the battery is to be considered fully charged; charging thebattery to a terminal voltage in excess of the open circuit voltage atwhich the battery is to be considered fully charged; terminating thecharging when the predicted open circuit voltage of the battery reachesthe open circuit voltage at which the battery is to be considered fullycharged independent on the load on the battery.
 8. The method of claim 7wherein the fuel gauge is a coulomb counter.
 9. The method of claim 8wherein the coulomb count of the coulomb counter from full to empty isadjusted up or down based on an error between the open circuit voltageof the empty battery after relaxation and the intended open circuitvoltage of the battery representing empty, and the coulomb count fromempty to full is adjusted up or down for the next charge cycle based onan error between the open circuit voltage of the battery afterrelaxation and the intended open circuit voltage of the batteryrepresenting full.
 10. The method of claim 1 wherein the battery ismodeled by: a fuel gauge that predicts the open circuit voltage of abattery responsive to at least one of a terminal voltage of the batteryand current out of the battery, even when the battery is under a load;monitoring at least one terminal voltage of the battery or the currentout of the battery.
 11. The method of claim 10 wherein the fuel gauge isa voltage model fuel gauge, and the at least one of the terminal voltageof the battery and current out of the battery is the terminal voltage ofthe battery.
 12. The method of claim 11 wherein the fuel gauge includesa coulomb counter, and the at least one of the terminal voltage of thebattery and current out of the battery is both the terminal voltage ofthe battery and the current in and out of the battery.
 13. The method ofclaim 10 wherein the fuel gauge is a coulomb counter, the at least oneof the terminal voltage of the battery or current out of the battery isthe current out of the battery, and the coulomb count from full to emptyis adjusted up or down for the next charge discharge cycle based on anerror between the open circuit voltage of the battery after relaxationand the intended open circuit voltage of the battery representing empty.14. A method of charging a rechargeable battery to a full state of thebattery comprising: providing a fuel gauge that predicts the opencircuit voltage of the battery responsive to a terminal voltage of thebattery and current to and from of the battery, even when the battery isunder a load or being charged, the fuel gauge having a voltage modelfuel gauge and a coulomb counter; monitoring the terminal voltage of thebattery and the current in and out of the battery; charging the batteryto a terminal voltage exceeding a predetermined full state batteryvoltage; and terminating the charging of the battery when the predictedopen circuit voltage is equal to a predetermined full state batteryvoltage.
 15. The method of claim 14 wherein the coulomb count from emptyto full is adjusted up or down for the next discharge charge cycle basedon an error between the open circuit voltage of the battery afterrelaxation and the intended open circuit voltage of the batteryrepresenting full.
 16. The method of claim 14 wherein the coulomb countfrom full to empty is adjusted up or down for the next charge dischargecycle based on an error between the open circuit voltage of the batteryafter relaxation and the intended open circuit voltage of the batteryrepresenting empty.
 17. The method of claim 14 further comprisingterminating a load on a battery when an empty state of the battery isreached comprising: determining when the predicted open circuit voltageis equal to a predetermined empty state battery voltage; and terminatingthe load when the predicted open circuit voltage of the battery reachesthe predetermined open circuit voltage of an empty battery.